Description:A BATTERY PACK
TECHNICAL FIELD
[0001] The present subject matter relates generally to a battery pack. More particularly but not exclusively the present subject matter relates to thermal 5 management of the battery pack.
BACKGROUND
[0002] With the advancement in technology, an electric or hybrid electric vehicle makes use of one or more power sources to drive the vehicle. The one or more 10 powers source is a battery pack to provide power to run a motor which in turn runs one or more wheels of the vehicle. The one or more power sources in such hybrid electric vehicles are prone to damage due to increase in temperature as the usage increases.
[0003] The battery pack includes the plurality of cells which are connected through 15 one or more interconnectors. The one or more interconnectors provide an electrical connection between each of the one or more cells. The plurality of cells are arranged in a module consisting of a top casing and a bottom casing. The plurality of cells are welded to a metal strip known as the interconnector, forming a battery pack. The one or more interconnectors are connected to a Battery management system 20 (BMS ). The BMS obtains individual parameters of the plurality of cells to monitor the State of Charge (SoC) and State of Health (SoH) of the battery pack. An efficient thermal management system can monitor a plurality of parameters associated with the battery pack. The plurality of parameters may comprise at least one of temperature, voltage, charging current, and the like. 25 [0004] Interconnectors employed in battery packs are configured to provide a secure electrical connection between the cells deployed in the battery pack. The structural design of electrical interconnectors in battery packs critically affect the performance, cost, and reliability of the battery pack.
Classification: Internal
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[0005] The repercussions of an improper interconnector design for a battery pack are associated with cell imbalances in the battery pack and error in row-to-row voltage measurements in the battery pack. Thus, there is a requirement of an optimized mechanical design of interconnectors which will improve the performance of the battery pack whilst reducing manufacturing cost and increasing 5 manufacturing feasibility of the battery pack. An optimized interconnector design additionally achieves uniform current distribution and uniform temperature distribution in the battery pack for alleviating the thermal stress on cells of the battery pack. Thermal stresses in the battery pack cause dire safety issues and reduced life of the battery pack. 10 [0006] Conventional battery packs are assembled using bulky metal plates wired using connecting wires or fusing wires to individual cells of the battery pack to serve the function of the interconnector. The connecting wires and fusing wires protect the individual cells of the battery pack against over-currents and thermal runaways. The fusing wires are fragile and are prone to breakage due to stress and 15 vibrations encountered by the battery pack during operation. The existing design of the battery pack comprising of bulky metal plates and connecting wires results in excess weight of the battery pack, associated costs, and overall complexity in the manufacturing of the battery pack. Additionally, safety and robust performance of battery packs is compromised owing to complex battery pack design. 20 [0007] In conventional battery packs, there are multiple interconnectors connecting the plurality of cells. These interconnectors are individually connected with the plurality of cells. Therefore, there is an increase in complexity of battery pack design and there is also an increase in the number of components that employed in the battery pack. 25
[0008] Another aspect of battery packs is thermal management which is a critical aspect of battery design and operation, as batteries can generate heat during charging and discharging. Excessive heat can lead to reduced battery life, safety risks, and even failure or fire. There are several ways to manage thermal issues in
Classification: Internal
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batteries, including - Thermal management systems, Cell design wherein battery manufacturers can design cells with features that help manage temperature, such as larger surface areas, thin or flexible substrates, and materials with high thermal conductivity, the choice of electrolyte can also impact thermal management.
[0009] The increase in temperature of the battery pack leads to poor performance 5 of the vehicle and cause thermal runaway, in turn creating unsafe driving conditions for a user. Thermal runaways are caused due to an abnormal increase in temperature inside the battery pack which may lead to the melting or excessive damage to a plurality of cells of the battery pack and may even cause the plurality of cells of the battery pack to explode. In the case of charged Li-ion cells with high energy density, 10 the thermal runaway is a fast, violent, self-accelerating chemical reaction of electrodes and electrolyte which releases high amounts of heat and gas. A better cooled battery pack ensures the welfare and safety of the user and as well as leads to an increase in durability and health of the plurality of cells of the battery pack. Moreover, electronic devices in the battery pack also generate heat due to the flow 15 of electricity through their circuits and components. It is extremely pertinent that the heat is dissipated effectively, to ensure that damage to the device is avoided and there is no reduction in the performance of the battery pack.
[00010] To tackle the increase in temperature of a battery pack, various methods are used. Active cooling methods involve using external power sources to transfer heat away from the device. Some examples of active cooling methods include forced air cooling, liquid cooling, and thermoelectric cooling. Forced air cooling involves using fans or blowers to circulate air over the device and dissipate heat. Liquid cooling, on the other hand, uses a liquid coolant, such as water or a specialized fluid, to absorb and remove heat from the device. Thermoelectric cooling uses the Peltier effect to transfer heat from one side of a thermoelectric device to the other, where it can be dissipated into the environment.
[00011] Passive cooling, on the other hand, uses no external energy source and relies on natural processes to remove heat from the device. Some examples of passive cooling methods include natural convection, radiation, and phase-change
Classification: Internal
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materials. Natural convection involves the movement of air due to temperature differences, while radiation involves the transfer of heat through electromagnetic waves. Phase-change materials, such as wax or paraffin, absorb and release heat as they change between solid and liquid states, providing a way to regulate temperature without external energy input.
[00012] Existing battery packs comprise of a phase change material (PCM). The PCM is a semi solid material which extracts heat from the plurality of cells, thus assists in maintaining optimum temperature of the battery pack for efficient functioning. When the temperature of the battery pack increases, the PCM changes its state from the semi solid to a liquid state. Due to which the side casings come in contact with the liquid PCM. Thus, additional components of the battery, such as a venting structure, electrical boards and components, which are located in the battery pack also come in contact with the liquid PCM, which may reduce the efficiency of the components and its functioning. Additionally, the PCM fails to dissipate heat from the components or portions of the cells where a high amount of heat is generated, thereby decreasing the efficiency of usage of the PCM.
[00013] Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art, through comparison of described systems with some aspects of the present disclosure, as set forth in the remainder of the present application and with reference to the drawings.
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SUMMARY OF THE INVENTION
[00014] According to embodiments illustrated herein, the present invention provides a tray assembly for a battery pack comprising a plurality of filling provisions, a base comprising a plurality of openings, a plurality of interconnectors 10 are securely attached to the base of the tray assembly via the plurality of openings. The plurality of interconnectors are configured to electrically connect the plurality of cells of the battery pack. The plurality of filling provisions are disposed on one
Classification: Internal
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or more sides of the tray assembly. The plurality of filling provisions are configured to dispense a cooling material between the base and at least one of a first casing and a second casing of the battery pack.
[00015] According to embodiments illustrated herein, the present invention provides a battery pack. The battery pack comprises at least of a casing comprising 5 a first casing (102a) and a second casing. The battery pack further comprises of a one or more tray assemblies and a plurality of cells which are housed in the casing. The one or more tray assemblies are dispensed between the plurality of cells and at least a first casing and a second casing to form a region between the one or more tray assemblies and at least a first casing and a second casing. A cooling material is 10 disposed in the region to enable dissipation of heat generated by the plurality of cells through the casing to surrounding atmosphere.
[00016] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed. 15
BRIEF DESCRIPTION OF THE DRAWINGS
[00017] The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by 20 way of illustration only, and thus are not limitative of the present invention.
[00018] The details are described with reference to an embodiment of a fire mitigation and venting system along with the accompanying diagrams. The same numbers are used throughout the drawings to reference similar features and components. 25
[00019] Figure 1 illustrates an assembled battery pack in accordance with an embodiment of the present disclosure.
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[00020] Figure 2A illustrates an exploded view of the battery pack depicting the various components of the battery pack in accordance with an embodiment of the present disclosure.
[00021] Figure 2B illustrates an exploded view of the tray assembly for a battery pack depicting the various components of the tray assembly and the disposition of 5 the cooling material in accordance with an embodiment of the present disclosure.
[00022] Figure 3A illustrates a perspective view of an assembled plurality of cells with the tray assembly for a battery pack in accordance with an embodiment of the present disclosure.
[00023] Figure 3B illustrates an exploded view of plurality of cells with the tray 10 assembly for a battery pack in accordance with an embodiment of the present disclosure.
[00024] Figure 4A illustrates a perspective view of assembled plurality of cells with the plurality of sheets in accordance with an embodiment of the present disclosure.
[00025] Figure 4B illustrates a perspective view of assembled plurality of cells with 15 the plurality of sheets and the tray assembly for a battery pack in accordance with an embodiment of the present disclosure.
[00026] Figure 5A illustrates a perspective view of assembled tray assembly for a battery pack in accordance with an embodiment of the present disclosure.
[00027] Figure 5B illustrates a perspective view of assembled tray assembly for a 20 battery pack in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
[00028] Exemplary embodiments are described with reference to the accompanying drawings. Wherever convenient, the same reference numbers are 25 used throughout the drawings to refer to the same or like parts. While examples and features of disclosed principles are described herein, modifications, adaptations,
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and other implementations are possible without departing from the spirit and scope of the disclosed embodiments. It is intended that the following detailed description be considered as exemplary only, with the true scope and spirit being indicated by the following claims.
[00029] An objective of the present subject matter is to provide a tray assembly for 5 a battery pack and the configuration of the tray assembly in the battery pack to dissipate the high temperatures generated by the plurality of cells due to cause a thermal runaway event instantly and protect the battery pack from exploding and causing harm to the user as well as regulate the flow of gases during thermal runaway. 10
[00030] It is another objective of the present subject matter to provide a battery pack with an optimized design, and uniform current distribution. The uniform current distribution enables achievement of uniform temperature distribution in the battery pack which reduces the occurrences of local temperature hotspots, thermal stresses as well as potential occurrences of thermal runaway in the battery pack. 15
[00031] Further, another objective of the present invention is to decrease the number of components in a battery pack, and thereby, decrease the weight of the battery pack. The use of fewer components reduces the weight of the battery pack which promotes the performance of the vehicle and increases the serviceability of the battery pack and the vehicle. 20
[00032] It is a further object of the present subject matter to provide a compact battery pack layout comprising of a plurality of cells with interconnectors connecting the plurality of cells.
[00033] It is an object of the present subject matter to provide an optimized design of a battery pack with a tray assembly configured to minimize number of 25 components and increase thermal management in the battery pack. The tray assembly along with the plurality of sheets reinforce and support the plurality of
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cells by arranging them in a pre-defined order and connecting them efficiently without multiple strips of interconnectors used.
[00034] As per an aspect of the present subject matter, the present invention provides a tray assembly for a battery pack comprising a plurality of filling provisions, a base comprising a plurality of openings, a plurality of interconnectors 5 are securely attached to the base of the tray assembly via the plurality of openings. The plurality of interconnectors are configured to electrically connect the plurality of cells of the battery pack. The plurality of filling provisions are disposed on one or more sides of the tray assembly. The plurality of filling provisions are configured to dispense a cooling material between the base and at least one of a first casing and 10 a second casing of the battery pack.
[00035] As per an aspect of the present subject matter, the tray assembly for a battery pack further comprises of a plurality of plugs which are configured to seal the plurality of filling provisions. The plurality of filling provisions are sealed to ensure that undesirable foreign matter does not enter into the battery pack. 15 Furthermore, the plurality of filling provisions enable an easy and simple assembly of the battery pack, thereby increasing the easy of serviceability of the battery pack.
[00036] As per an aspect of the present subject matter, the tray assembly for a battery pack is made of an electrically insulating and thermally conducting material. This enables an efficient and resourceful mechanism for thermal management. The 20 cooling material extracts the heat generated from the plurality of cells to the outer environment.
[00037] As per an aspect of the present subject matter, the cooling material is a Phase-Change Material (PCM), and a heat absorbing and releasing material. The cooling material is a eutectic mixture of bio-based phase change material. When the 25 temperature of the battery pack increases, the PCM extracts the heat generated in the plurality of cells, liquifies, and transfers the heat to the surrounding environment.
Classification: Internal
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[00038] As per an aspect of the present subject matter, the present invention provides a battery pack. The battery pack comprises at least of a casing comprising a first casing (102a) and a second casing. The battery pack further comprises of a one or more tray assemblies and a plurality of cells which are housed in the casing. The one or more tray assemblies are dispensed between the plurality of cells and at 5 least a first casing and a second casing to form a region between the one or more tray assemblies and at least a first casing and a second casing. A cooling material is disposed in the region to enable dissipation of heat generated by the plurality of cells through the casing to surrounding atmosphere.
[00039] As per an aspect of the present subject matter, the one or more tray 10 assemblies comprise of a plurality of interconnectors which are configured to electrically connect the plurality of cells of the battery pack. In contrast to the conventional battery packs, the present invention provides for a single component which can be used to connect the plurality of cells electrically. This leads to a decrease in multiple components, and easy assembly of the battery pack. 15
[00040] As per an aspect of the present subject matter, at least one of the one or more tray assemblies is disposed on a positive terminal of the plurality of cells and at least one of the one or more tray assemblies is disposed on a negative terminal of the plurality of cells. The plurality of cells generate a lot of heat through their terminals, instead of the body of the cells. Therefore, it was unnecessary for the 20 plurality of cells to be immersed in the cooling material entirely. The present invention efficiently disperses and dissipates the heat by establishing contact of the cooling material with the cell terminals, where maximum heat is generated. The plurality of interconnectors are bound to get heated during long duration of usage of the battery pack. The cooling material, as per an embodiment, is in contact with 25 the interconnectors which carry current and establish electrical contact between the plurality of cells.
[00041] As per an aspect of the present subject matter, the casing comprises of a first casing and a second casing. The first casing and the second casing are disposed
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on lateral sides of the battery pack to form the housing for the plurality of cells. As per another aspect of the present subject matter, at least one of the one or more tray assemblies is disposed between the positive terminal of the plurality of cells and the first casing. Furthermore, at least one of the one or more tray assemblies is disposed between the negative terminal of the plurality of cells and the second casing. The 5 present invention efficiently dissipates the heat by establishing contact of the cooling material with the cell terminals, where maximum heat is generated and dissipates it to the surrounding environment through the casing of the battery pack. The containing of the cooling material between the tray assembly and the casing ensures that the cooling material does not spill onto other surrounding components, 10 consequently decreasing the life and efficiency of the battery pack.
[00042] As per an aspect of the present subject matter, the one or more tray assemblies comprising of a plurality of filling provisions which enable the dispensing of the cooling material in the region between the casing and the one or more tray assemblies. As per another aspect of the present subject matter, the 15 present invention provides a plurality of plugs to seal the plurality of filling provisions.
[00043] As per an aspect of the present subject matter, the one or more tray assemblies are made of an electrically insulating and thermally conducting material.
[00044] As per an aspect of the present subject matter, the present invention 20 provides a plurality of sheets which are configured to hold and support the plurality of cells in a pre-defined configuration. The plurality of sheets maintain the required cell arrangement and cell spacing. As per another aspect of the present subject matter, the plurality of sheets comprising a plurality of holes which are cut out in the plurality of sheets to receive the plurality of cells. The plurality of cells are 25 disposed in the cut out plurality of holes in the sheets to arrest the movement of the plurality of cells. This eliminates the need for an additional cell holder, thereby decreasing the number of components in the battery pack and thus, reducing the
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weight of the battery pack. To further strengthen and arrest the movement of the plurality of cells, in an embodiment, a first material is disposed between the plurality of sheets to form a rigid structure and support the plurality of cells. In another embodiment, the first material may be an epoxy resin, or a polymer, or a polyurethane, or a combination thereof. The insertion of the first material between 5 the plurality of sheets increases the rigidity of the structure, and ensures that the plurality of cells remain the pre-defined arrangement as intended.
[00045] As per an aspect of the present subject matter, to ensure that the heat dissipation is done efficiently and the battery pack is strengthened, the casing may be made of thermally conductive material, and the casing may be made of 10 aluminium, a metal alloy, or a combination thereof.
[00046] The embodiments of the present invention will now be described in detail with reference to a battery pack along with the accompanying drawings. However, the present invention is not limited to the present embodiments. The present subject matter is further described with reference to accompanying figures. It should be 15 noted that the description and figures merely illustrate principles of the present subject matter. Various arrangements may be devised that, although not explicitly described or shown herein, encompass the principles of the present subject matter. Moreover, all statements herein reciting principles, aspects, and examples of the present subject matter, as well as specific examples thereof, are intended to 20 encompass equivalents thereof.
[00047] Figure 1 illustrates an assembled battery pack in accordance with an embodiment of the present disclosure. Figure 1 shows, a battery pack (100) and the casing (102). The casing houses a plurality of cells (212) disposed to hold it in its required position, during the operation of the vehicle (not shown). The plurality of 25 cells (212) provides the electric energy to drive a vehicle (not shown). A plurality of interconnectors (204) is used to make electrical connection between the plurality of cells (212). The plurality of cells (212) may be welded to the plurality of interconnectors (204). In an embodiment, the battery pack comprises of a top casing
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(not shown) that covers the battery pack from a top portion. In an embodiment, the battery pack comprises of a bottom casing which provides a support to the battery pack. In an embodiment, the casing 102 can be one of the aluminum casings.
[00048] Figure 2A illustrates an exploded view of the battery pack depicting the various components of the battery pack in accordance with an embodiment of the 5 present disclosure. Figure 2B illustrates an exploded view of the tray assembly for a battery pack depicting the various components of the tray assembly and the disposition of the cooling material in accordance with an embodiment of the present disclosure. For brevity, Figure 2A and 2B will be explained together. In the present embodiment, the casing (102) comprises of a first casing (102a) and a second casing 10 (102b) which accommodates a plurality of cells (212) and supports the one or more sides of the battery pack. The battery pack (100) comprises of a casing (102), a plurality of cells (212), and one or more tray assemblies (200). The plurality of cells (212) are housed in the casing (102). The one or more tray assemblies (200) are disposed between the casing (102) and the plurality of cells (212) to form a region 15 between the casing (102) and the one or more tray assemblies (200). A cooling material (106) is disposed in the region to enable dissipation of heat generated by the plurality of cells (212) through the casing (102) to surrounding atmosphere. The cooling material (106) is a Phase-Change Material (PCM), and a heat absorbing and releasing material. The cooling material (106) is a eutectic mixture of bio-based 20 phase change material. When the temperature of the battery pack increases, the PCM extracts the heat generated in the plurality of cells, liquifies, and transfers the heat to the surrounding environment.
[00049] The tray assembly (200) is configured to hold the one or more interconnectors (204) in place together. Therefore, to connect the plurality of cells 25 (212), the tray assembly holds the plurality of interconnectors (204) on each terminal of the plurality of cells (212). At least one of the one or more tray assemblies (200) is disposed on a positive terminal of the plurality of cells (212) and at least one of the one or more tray assemblies (200) is disposed on a negative
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terminal of the plurality of cells (212). The cooling material (106) is adjacent to the casing (102), thereby efficiently dissipating the heat to the surround atmosphere through the casing (102). The plurality of interconnectors (204) are attached to the base of the tray assembly (206), and the plurality of interconnectors (204) are further connected to the plurality of cells (212). The plurality of cells (212) are held 5 together by a plurality of sheets (210) which bring rigidity to the structure of the plurality of cells (212) and arrest the movement of the plurality of cells (212). Such an arrangement is made on both sides of the battery, with respect to the first casing (102a) and the second casing (102b). The maximum heat generated is in the terminals of the plurality of cells (212), therefore, the cooling material (106) 10 efficiently comes into contact with the terminals of the plurality of cells (212). This in turn also decreases the amount of cooling material (106) dispensed into the battery pack (100) further decreasing the weight of the battery pack. As seen in Figure 2B, the plurality of interconnectors (204) are attached to the base of the tray (206). A plurality of plugs (214) are used to seal the filling provisions (see figure 15 5A) provided on the one or more sides of the one or more tray assemblies (200) to avoid the entry of water and other undesirable foreign matter.
[00050] Figure 3A illustrates a perspective view of an assembled plurality of cells with the tray assembly for a battery pack in accordance with an embodiment of the present disclosure. Figure 3B illustrates an exploded view of plurality of cells with 20 the tray assembly for a battery pack in accordance with an embodiment of the present disclosure. For brevity, Figure 3A and 3B will be explained together. At least one of the one or more tray assemblies (200) is disposed on a positive terminal of the plurality of cells (212); and at least one of the one or more tray assemblies (200) is disposed on a negative terminal of the plurality of cells (212). In an 25 embodiment as presented in the present subject matter, the plurality of cells (212) are disposed in a lateral direction in the battery pack (100). Therefore, the terminals of the plurality of cells (212) are adjacent to the first casing (102a) and the second casing (102b). In an embodiment, the casing (102) is made of thermally conductive
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material to aid in thermal management of the battery pack (100). In another embodiment, the casing (102) is made of aluminium, a metal alloy, or a combination thereof.
[00051] A provision of power terminal (302) is provided on one or more sides of the one or more tray assemblies (200). This power terminal (302) is connected 5 further to positive and negative terminals of the motor (not shown). In an embodiment, the one or more tray assemblies (200) are made of an electrically insulating and thermally conducting material.
[00052] Figure 4A illustrates a perspective view of assembled plurality of cells with the plurality of sheets in accordance with an embodiment of the present 10 disclosure. Figure 4B illustrates a perspective view of assembled plurality of cells with the plurality of sheets and the tray assembly for a battery pack in accordance with an embodiment of the present disclosure. For brevity, Figure 4A and 4B will be explained together. In an embodiment, the battery pack (100) comprises of a plurality of sheets (210) which are configured to hold and support the plurality of 15 cells (212) in a pre-defined configuration. The plurality of sheets (210) comprising a plurality of holes (210a), which are cut out in the plurality of sheets (210) to receive the plurality of cells (212). The plurality of cells (212) are fit into theses plurality of holes (210a) and are snugly fit into the sheet (210). In an embodiment, a first material is disposed between the plurality of sheets (210) to form a rigid 20 structure and support the plurality of cells (212). This first material may be an epoxy resin, or a polymer, or a polyurethane, or a combination thereof. The plurality of sheets (210) maintain the required cell arrangement and cell spacing.
[00053] Figure 5A illustrates a perspective view of assembled tray assembly for a battery pack in accordance with an embodiment of the present disclosure. Figure 25 5B illustrates a perspective view of assembled tray assembly for a battery pack in accordance with an embodiment of the present disclosure. For brevity, Figure 5A and Figure 5B are explained together. The tray assembly (200) comprises of a base of tray assembly (206) and a plurality of interconnectors (204). The plurality of
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interconnectors (204) are mounted on the base of the tray assembly (206). A plurality of filling provisions (214a) are provided on one or more sides of the tray assembly (200) to enable the dispensing of the cooling material (106) in the battery pack (100). These filling provisions (214a) are sealed with a plurality of plugs (214). The tray assembly (200) holds all the interconnectors (204) together to 5 increase ease in assembly.
[00054] The present invention is advantageous to protect the battery pack from overheating of the plurality of cells and prevent thermal runaway of the battery pack. Overheating of the plurality of cells in a battery pack leads to decrease in cell life and the performance efficiency of the battery pack. Temperature monitoring of 10 the plurality of cells in a battery pack plays a crucial role in optimisation of parameters like state of charge (SoC) linked to performance, state of health (SoH) linked to battery lifetime. Moreover, such monitoring is beneficial to a user safety aspect.
[00055] The present invention advantageously disposes the one or more tray 15 assemblies on the positive and negative terminals of the plurality of cells. The plurality of cells generate a lot of heat through their terminals, instead of the body of the cells. Therefore, it is unnecessary for the plurality of cells to be immersed in the cooling material entirely. The present invention efficiently disperses and dissipates the heat by establishing contact of the cooling material with the cell 20 terminals, where maximum heat is generated. The plurality of interconnectors are bound to get heated during long duration of usage of the battery pack. The cooling material, as per an embodiment, is in contact with the interconnectors which carry current and establish electrical contact between the plurality of cells. This in turn also decreases the amount of cooling material dispensed into the battery pack 25 further decreasing the weight of the battery pack. The present invention also eliminates the spillage of cooling material onto surrounding components of the battery pack and contains the cooling material in the space between the tray assembly and the casing.
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[00056] The present invention will aid in increasing the performance of the battery pack, along with durability of the battery pack and safety of the user. The use of fewer components reduces the weight of the battery pack which promotes the performance of the vehicle and increases the serviceability of the battery pack and the vehicle. 5
[00057] The present invention eliminates the need for an additional by providing sheets which reinforce the plurality of cells in their pre-defined arrangement. The plurality of sheets may be made of a thermally conductive and electrically insulating material, to enable efficient heat dissipation while also safeguarding the user by electrically insulating the plurality of cells in case of leakage or any other 10 hazardous conditions.
[00058] In accordance with the configuration of the interconnector having an optimized design, uniform current distribution in the battery pack is achieved. The uniform current distribution enables achievement of uniform temperature distribution in the battery pack which reduces the occurrences of local temperature 15 hotspots, thermal stresses as well as potential occurrences of thermal runaway in the battery pack.
[00059] In conventional battery packs, the interconnectors comprises of bulky metal plates with connecting wires which tend to loosen upon being subjected to external shocks, vibrations and stresses. The present disclosure addresses this exact 20 drawback of the conventional battery packs and protects the battery pack against malfunction, unprecedented halt in functioning and potential safety hazards.
[00060] In accordance with the configuration of the disclosed subject matter, an additional advantage of the disclosed battery pack is the flexibility to manufacture variants in forms of size of the battery pack, range of power supply and capacity of 25 the battery pack. The disclosed tray assembly for a battery pack design can be easily implemented and modified in accordance with the electrical demands of the external electrical load.
Classification: Internal
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[00061] In accordance with the configuration of the tray assembly for a battery pack, the battery pack comprising of the disclosed tray assembly achieves ease of manufacturing and manufacturing feasibility of the battery pack without major revamping of conventional manufacturing processes. The disclosed subject matter enables implementation in modified versions of existing battery packs with minimal 5 changes in the battery pack design, electrical connections in the battery pack and even the manufacturing set-up. The reduced weight, component cost further makes the present subject matter as a cost-efficient solution addressing the limitations and drawbacks of conventional battery packs.
[00062] In conventional battery packs, bulky metal plates and connecting wires are 10 employed to individually connect cells of the battery pack. The disposition of bulky metal plates and connecting wires increases the overall weight, component cost as well as complicates the layout of the battery pack. The drawbacks associated with conventional battery pack designs adversely affect manufacturability, serviceability, ease of assembly, accessibility and maintenance of the battery pack. 15
[00063] In view of the above, the claimed limitations as discussed above are not routine, conventional, or well understood in the art, as the claimed limitations enable the above solutions to the existing problems in conventional technologies.
[00064] The present subject matter is described using a battery pack, whereas the claimed subject matter can be used in any other type of application employing 20 above-mentioned battery pack assembly configuration, with required changes and without deviating from the scope of invention. Further, it is intended that the disclosure and examples given herein be considered as exemplary only.
[00065] The terms “an embodiment”, “embodiment”, “embodiments”, “the embodiment”, “the embodiments”, “one or more embodiments”, “some 25 embodiments”, and “one embodiment” mean “one or more (but not all) embodiments of the invention(s)” unless expressly specified otherwise. The terms “including”, “comprising”, “having” and variations thereof mean “including but not
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limited to”, unless expressly specified otherwise. The terms “a”, “an” and “the” mean “one or more”, unless expressly specified otherwise.
[00066] A description of an embodiment with several components in communication with another does not imply that all such components are required, On the contrary, a variety of optional components are described to illustrate the 5 wide variety of possible embodiments of the invention,
[00067] Finally, the language used in the specification has been principally selected for readability and instructional purposes, and it may not have been selected to delineate or circumscribe the inventive subject matter and is therefore intended that the scope of the invention be limited not by this detailed description, but rather by 10 any claims that issue on an application based here on. Accordingly, the embodiments of the present invention are intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
[00068] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various 15 aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
[00069] A person with ordinary skills in the art will appreciate that the systems, modules, and sub-modules have been illustrated and explained to serve as examples 20 and should not be considered limiting in any manner. It will be further appreciated that the variants of the above disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different systems or applications.
[00070] Those skilled in the art will appreciate that any of the aforementioned steps 25 and/or system modules may be suitably replaced, reordered, or removed, and additional steps and/or system modules may be inserted, depending on the needs of a particular application.
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[00071] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without 5 departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended claims.
Classification: Internal
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List of Reference numerals
100 – Battery pack
102 – casing
102a – first casing 5
102b – second casing
106 – cooling material
200 – Tray assembly
204 – plurality of interconnectors
206 – tray base 10
210 – plurality of sheets
210a –holes in sheets
212 - cells
214 - plurality of plugs
214a – filling provision , Claims:Claims
We claim:
1. A tray assembly (200) for a battery pack (100), the tray assembly (200) comprising:
a base (206) comprising a plurality of openings;
a plurality of interconnectors (204) being securely attached 5 to the base (206) of the base (206) via the plurality of openings,
wherein the plurality of interconnectors (204) being configured to electrically connect the plurality of cells (212) of the battery pack (100), 10
a plurality of filling provisions (214a), the plurality of filling provisions (214a) being disposed on one or more sides of the tray (200) assembly,
wherein the plurality of filling provisions (214a) being configured to dispense a cooling material (106) 15 between the base (206) and at least one of a first casing (102a) and a second casing (102b) of the battery pack (100).
2. The tray (200) for the battery pack (100) as claimed in claim 1 comprising 20 of a plurality of plugs (214), wherein the plurality of plugs (214) being configured to seal the plurality of filling provisions (214a).
3. The tray (200) for the battery pack (100) as claimed in claim 1, wherein the tray (200) being made of an electrically insulating and thermally conducting 25 material.
Classification: Internal
23
4. The tray (200) for the battery pack (100) as claimed in claim 1, wherein the cooling material (106) being a Phase-Change Material (PCM), wherein the PCM being a eutectic mixture of bio-based phase change material.
5. A battery pack (100), the battery pack (100) comprising: 5
a casing (102) comprising a first casing (102a) and a second casing (102b),
a plurality of cells (212),
wherein the plurality of cells (212) being housed in the casing (102); 10
one or more tray assemblies (200),
wherein the one or more tray assemblies (200) being dispensed between the plurality of cells (212) and at least a first casing (102a) and a second casing (102b) to form a region between the one or more tray assemblies (200) 15 and at least a first casing (102a) and a second casing (102b),
wherein a cooling material (106) being disposed in the region to enable dissipation of heat generated by the plurality of cells (212) through the casing 20 (102) to surrounding atmosphere.
6. The battery pack (100) as claimed in claim 5, wherein each of the one or more tray assemblies (200) comprising of a plurality of interconnectors (204), the plurality of interconnectors (204) being configured to electrically 25 connect the plurality of cells (212) of the battery pack (100).
Classification: Internal
24
7. The battery pack (100) as claimed in claim 5, wherein at least one or more of the tray assemblies (200) being disposed on a positive terminal of the plurality of cells (212); wherein at least one of the one or more tray assemblies (200) being disposed on a negative terminal of the plurality of cells (212). 5
8. The battery pack (100) as claimed in claim 5, wherein the casing (102) comprises of a first casing (102a) and a second casing (102b), wherein the first casing (102a) and the second casing (102b) being disposed on lateral sides of the battery pack (100) to form the housing for the plurality of cells 10 (212).
9. The battery pack (100) as claimed in claim 5, wherein the one or more tray assemblies comprising of a plurality of filling provisions (214a), wherein the plurality of filling provisions (214a) being configured to dispense the 15 cooling material (106) in the region between the casing (102) and the one or more tray assemblies(200).
10. The battery pack (100) as claimed in claim 9, comprising of a plurality of plugs (214), wherein the plurality of plugs (214) being configured to seal 20 the plurality of filling provisions (214a).
11. The battery pack (100) as claimed in claim 5, wherein the one or more tray assemblies (200) being made of an electrically insulating and thermally conducting material. 25
12. The battery pack (100) as claimed in claim 5, comprising of a plurality of sheets (210), wherein the plurality of sheets (210) being configured to hold and support the plurality of cells (212) in a pre-defined configuration, and
Classification: Internal
25
wherein the plurality of sheets (210) comprising a plurality of holes (210a), wherein the plurality of holes (210a) being cut out in the plurality of sheets (210)to receive the plurality of cells (212).
13.The battery pack (100) as claimed in claim 12, wherein a first material being5 disposed between the plurality of sheets (210) to form a rigid structure andsupport the plurality of cells (212), wherein the first material being an epoxyresin, or a polymer, or a polyurethane, or a combination thereof.
14.The battery pack (100) as claimed in claim 5, wherein the casing (102) being10 made of thermally conductive material, wherein the casing (102) beingmade of aluminium, a metal alloy, or a combination thereof.
15.The battery pack (100) as claimed in claim 5, wherein the cooling material(106)being a Phase-Change Material (PCM), wherein the PCM being a15
eutectic mixture of bio-based phase change material. Dated 26th day of July 2023